High Voltage Battery Pack R&R

Complete removal and replacement of the high voltage battery pack assembly on a 2023 Rivian EDV 500 electric delivery vehicle. This is a safety-critical procedure requiring specialized training and equipment.

Warnings

Tools required

Parts

• High voltage battery pack assembly × 1 — Use OEM specification - Rivian part number required
• Battery pack mounting bolt set × 1 — Replacement recommended - Use OEM specification
• HV connector seals/gaskets × 1 — Use OEM specification
• Battery thermal management system seals × 1 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Verify replacement battery pack part number matches vehicle specification and has been properly stored per Rivian requirements (temperature and charge state)
2. Ensure workshop is equipped with proper high voltage safety equipment including emergency shut-off procedures and first aid for electrical injury
3. Review Rivian high voltage safety training materials and emergency response procedures
4. Park vehicle on level surface with sufficient overhead clearance for lift operation
5. Apply parking brake and chock all four wheels
6. Ensure vehicle has been sitting unused for at least 1 hour with all systems powered down
7. Put on high voltage personal protective equipment (insulated gloves, face shield, arc-rated clothing)
8. Connect diagnostic scan tool and verify no active charging or high voltage system faults
9. Document battery pack state of charge, serial number, and any diagnostic trouble codes
10. Take photos of all electrical connections and routing for reference during reinstallation

Procedure

1. 1

   Disable High Voltage System
   Using diagnostic tool, command the vehicle into service mode to disable high voltage system. Remove the 12V service battery negative terminal first, then positive terminal. Wait 5 minutes. Access the high voltage service disconnect located in the rear cargo area behind the driver-side panel. Using the service disconnect tool, remove the HV service plug by rotating counterclockwise and pulling straight out. Install insulating cover over the exposed connector. Verify complete system shutdown by checking for zero voltage at designated HV test points using insulated multimeter. Wait an additional 15 minutes for capacitor discharge.
   ⚠️Do not proceed until multimeter confirms 0V DC at all high voltage test points. Lethal voltage may still be present if capacitors have not fully discharged.
2. 2

   Drain Battery Thermal Management Coolant
   Place drain pan with minimum 12 quart capacity beneath vehicle. Locate the battery coolant drain valve on the underbody thermal management system. Attach drain hose to valve and open to drain coolant into collection pan. Once flow stops, close drain valve. Access the coolant reservoir in the front compartment and use suction tool to remove remaining coolant. Record amount of coolant drained for refill reference.
   ⚠EV coolant may still be warm. Ensure system has cooled before opening drain valve. Coolant is toxic and must be disposed of properly.
3. 3

   Raise Vehicle and Remove Underbody Panels
   Raise vehicle on lift to comfortable working height (approximately 5 feet). Ensure lift arms are positioned on designated lift points per Rivian service manual. Remove all underbody protective panels and skid plates to expose battery pack. This includes front, center, and rear underbody covers secured by multiple fasteners. Label and organize all fasteners by location for reinstallation.
   ⚠️Verify vehicle is stable on lift before working underneath. Battery pack adds significant weight low in chassis.
4. 4

   Disconnect Battery Thermal Management System
   Locate coolant hose connections at front and rear of battery pack (typically quick-disconnect type). Using appropriate tool, release coolant line quick-disconnects and separate coolant hoses from battery pack. Allow any residual coolant to drain into catch pan. Cap or plug all open coolant fittings to prevent contamination. Disconnect coolant temperature sensors and coolant pump electrical connectors if present on battery pack assembly.
5. 5

   Disconnect High Voltage Power Connections
   Wearing HV gloves and using insulated tools only, identify the high voltage busbars connecting battery pack to drive units. These are typically orange-colored connections with covers. Remove protective covers from HV connections. Using insulated tools, remove mounting bolts securing HV positive and negative busbars to battery pack terminals. Carefully separate busbars from battery pack terminals and secure them away from work area with insulating caps installed on exposed terminals. Verify zero voltage at exposed battery terminals with multimeter.
   ⚠️Even with service disconnect removed, verify zero voltage before touching HV terminals. Never allow HV positive and negative terminals or conductors to contact each other or vehicle ground.
6. 6

   Disconnect Battery Management System Wiring
   Locate and disconnect all low-voltage wiring harness connectors to the Battery Management System (BMS). This typically includes multiple connectors along the side or top of battery pack for cell monitoring, temperature sensors, and contactors. Release connector locks and carefully disconnect each connector. Tag each connector with its location for proper reconnection.
7. 7

   Position Battery Pack Support Fixture
   Carefully position battery pack lift table or heavy-duty transmission jack beneath the center of the battery pack. Raise lift table until it just contacts battery pack, but does not support full weight. Install safety straps across battery pack to secure it to lift table. Ensure lift table is positioned to maintain balance when battery pack mounting bolts are removed. Battery pack center of gravity should be centered on lift table.
8. 8

   Remove Battery Pack Mounting Bolts
   Locate all battery pack mounting bolts securing pack to vehicle frame rails and subframe (typically 16-24 bolts around perimeter). Using appropriate socket, begin removing mounting bolts in a cross-pattern starting from the center and working outward. Leave corner bolts partially threaded until all others are removed. Support battery pack weight with lift table before removing final bolts. Remove remaining bolts and ensure battery pack is fully supported by lift table.
   ⚠️Battery pack weighs approximately 1,800 lbs. Ensure lift table is properly rated and positioned. Never allow any body part under unsupported battery pack.
9. 9

   Lower and Remove Battery Pack
   With assistant helping guide the pack, slowly and carefully lower battery pack using lift table. Watch for any snagged wires or hoses. Lower pack approximately 12 inches, then verify all connections are clear. Continue lowering to ground level. Carefully roll lift table with battery pack out from under vehicle. Transport old battery pack to designated storage area. Keep battery pack level and avoid any impacts during handling.
   ⚠Monitor clearances carefully as pack is lowered. Battery pack must remain level to prevent internal damage to cells.
10. 10

    Inspect Mounting Points and Clean Surfaces
    With battery pack removed, thoroughly inspect frame mounting points, threaded inserts, and battery pack mounting surfaces for damage, corrosion, or contamination. Clean all mounting surfaces with wire brush and solvent. Inspect HV terminal mounting surfaces on vehicle side for corrosion or damage. Apply dielectric grease to HV terminal contact surfaces. Verify all threaded holes are clean and threads are in good condition.
11. 11

    Prepare and Position New Battery Pack
    Inspect new battery pack for any shipping damage. Verify part number and serial number match vehicle specifications. Document new battery pack information. Remove any shipping brackets or protective covers. Install new thermal management seals and HV connector seals per Rivian specifications. Position new battery pack on lift table with same orientation as removed pack. Apply dielectric grease to HV terminals on battery pack. Carefully roll lift table with new battery pack under vehicle, aligning pack with mounting points.
12. 12

    Raise and Align Battery Pack
    Slowly raise battery pack using lift table, stopping periodically to check alignment with mounting holes. Use pry bar if necessary to make minor alignment adjustments. Continue raising until battery pack is fully seated against mounting points on frame rails. Install 2-4 mounting bolts finger-tight at corners to hold pack in position. Verify proper alignment of all mounting holes before proceeding.
13. 13

    Install Battery Pack Mounting Bolts
    Install all remaining battery pack mounting bolts finger-tight. Starting from the center and working outward in a cross-pattern, tighten mounting bolts in three stages: first to 25% of final torque, then 50%, then final torque. Without torque specifications in database, follow Rivian service manual specifications exactly. Do not over-tighten. Verify all bolts are properly seated and torqued.
    ⚠Critical structural connection - use only specified torque values from Rivian service manual. Over-torquing can damage battery pack housing or mounting points.
14. 14

    Reconnect High Voltage Power Connections
    Wearing HV gloves, carefully position HV busbars onto battery pack terminals. Verify proper polarity (positive to positive, negative to negative). Install mounting hardware and torque per Rivian specifications using insulated tools. Apply dielectric grease to connections. Install protective covers over HV connections. Double-check that all HV connections are secure and properly insulated before proceeding.
    ⚠️Reversed polarity will cause catastrophic system damage. Verify positive and negative connections three times before tightening.
15. 15

    Reconnect Battery Management System and Coolant Lines
    Reconnect all BMS wiring harness connectors to battery pack using reference photos and tags. Ensure all connector locks click into place. Reconnect coolant temperature sensors and pump connectors. Connect coolant quick-disconnect fittings to battery pack, ensuring they lock properly. Verify all coolant connections are secure and properly seated.
16. 16

    Refill Battery Thermal Management Coolant
    Using EV-specific battery/motor coolant, fill thermal management system through reservoir to proper level (approximately 10 quarts total, adjust based on amount drained). Follow Rivian bleeding procedure to remove air from system. This typically involves running coolant pump through diagnostic tool while adding coolant. Continue until no air bubbles are present and coolant level stabilizes. Verify no leaks at all coolant connections.
17. 17

    Reinstall Underbody Panels and Lower Vehicle
    Reinstall all underbody protective panels and skid plates in reverse order of removal. Ensure all fasteners are properly seated and tightened. Verify no tools or parts were left in underbody area. Lower vehicle to ground level. Remove wheel chocks.
18. 18

    Reconnect 12V Battery and Enable High Voltage System
    Reconnect 12V service battery positive terminal first, then negative terminal. Using diagnostic scan tool, clear any stored fault codes and perform battery pack registration procedure per Rivian requirements. This programs new battery pack serial number and initializes BMS. Install HV service disconnect plug by inserting straight and rotating clockwise until locked. Remove insulating cover. Exit service mode using diagnostic tool.
19. 19

    Perform System Verification and Testing
    With diagnostic tool connected, command high voltage system to ready state and monitor for proper voltage readings (should see approximately 400V DC at pack level). Verify all BMS modules communicate properly and show no faults. Check coolant system for leaks with system operating. Perform battery pack isolation resistance test per Rivian procedure (should show >500 ohms to chassis ground). Verify all HV contactors operate correctly. Test drive vehicle and monitor battery performance, temperature, and charging systems.

Reassembly

1. Torque all battery pack mounting bolts to Rivian specifications in proper sequence
2. Verify all high voltage connections are properly torqued and insulated before energizing system
3. Install new seals and gaskets - do not reuse old thermal management or HV connector seals
4. Use fresh EV-specific battery coolant only - do not mix coolant types
5. Perform complete coolant system bleeding procedure to prevent overheating
6. Apply dielectric grease to all HV terminal connections
7. Route all wiring harnesses in original positions using reference photos

Verification

• Using diagnostic scan tool, verify new battery pack is properly registered to vehicle and shows correct serial number
• Confirm zero diagnostic trouble codes related to high voltage system or battery management
• Verify battery pack voltage is within normal range (typically 350-420V DC depending on state of charge)
• Check battery isolation resistance is >500 ohms to chassis ground
• Verify all BMS modules communicate and show balanced cell voltages
• Confirm coolant temperature sensors read properly and coolant pump operates
• Inspect all HV connections and coolant connections for leaks with system operating
• Test vehicle operation in both drive and reverse to verify drive units receive power
• Perform test charge to verify charging system functions properly with new pack
• Road test vehicle for minimum 15 miles monitoring battery temperature, voltage, and performance
• Re-check all mounting bolts for proper torque after test drive
• Document new battery pack installation including serial number, date, and mileage in vehicle service records

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